Most wheels are either cast or forged. FusionForge® is both, in that order, and we are the first company in the world to offer it. It came after twenty years of making wheels.
The wheel starts as a casting. Then the lip and the back of it get forged.
Locked in the mould. The cast piece is propped above a steel mould on a locking mechanism. That mechanism controls how the piece moves into the forging stage, so the metal ends up where we want it.
Three rollers. Extreme pressure shapes the aluminium against the mould, one side at a time. The rollers work, then return.
No heat, more strength. The shape changes under pressure alone. Nothing is heated, and the wheel comes out stronger for it.
What you get is a wheel that keeps the shape freedom of a casting and picks up strength where a truck wheel takes the hits: the lip and the back face. Every design passes a 3,700 lb safety test, and we still build them up to 25% lighter than most of the market.
Two designs carry the process today: Strike and Whipsaw. The rest of the line is one piece cast.
